Hanger bar



0a. 1, 1968 J. L. BROW ING 3,403,787

HANGER BAR Filed April 5. 1966 ZNVENTOR James LBrowmfny ATTORNEYS United States Patent 3,403,787 HANGER BAR James L. Browning, 1240 Utoy Springs Road SW., Atlanta, Ga. 30331 Filed Apr. 5, 1966, Ser. No. 540,237 Claims. (Cl. 211-124) ABSTRACT OF THE DISCLOSURE A hanger bar assembly having a hanger support bar over which a plurality of hooks or hangers are disposed for supporting articles of apparel on hangers from the hanger bar and a locking cap which has a flat upper surface and a pair of downwardly and outwardly projecting sides which overhang the sides of the support bar. The cap is removably retained in place by a plurality of longitudinally spaced clips which project through aligned apertures in the bar and wrap around a portion of the cap and the lower edge portion of the bar.

This invention relates to a hanger bar assembly and is more concerned with a combination hanger bar and locking cap for confining the hooks of hangers on which are disposed articles of clothing.

In the past, hanger bars for corrugated shipping containers have been extensively used. In deed, there are a number of hanger bars which are provided with elements which attempt to confine the hooks of the hangers. Generally speaking, these prior art devices are expensive, are diflicult to manipulate, do not do a good job of confining the hooks, and do not lend themselves well to the rapid packing and unpacking of a container.

Briefly described, the hanger bar assembly of the present invention includes an inverted channel member of trapezoidal cross-section, the ends of which are provided with inverted U-shaped hooks which project over the upper edges of the side panels of a corrugated wardrobetype shipping container or box. A locking cap is disposed over the upper surface or web of the hanger bar and is so constructed and arranged that it overlies the sides of the hanger bar. The cap is removably retained in place by a plurality of longitudinally spaced clips which project through aligned apertures in the bar and cap. The clips are of deformable metal and, when installed, are bent sidewise over the cap and around the bar so as to clamp, between the hanger bar and the locking cap, the hooks of the hangers which support the articles of apparel within the container.

Accordingly, it is an object of the present invention to provide a hanger bar assembly which is inexpensive to manufacture, durable in structure, and eflicient in operation.

Another object of the present invention is to provide a hanger bar assembly which will efl'iciently confine the hooks of hangers against lateral movement and against being inadvertently removed from the hanger bar.

Another object of the present invention is to provide a hanger bar assembly which will positively restrain the hooks of hanger bars disposed thereon, the restraining elements being quickly and easily assembled on the hanger bar and quickly and easily removed therefrom.

Another object of the present invention is to provide a hanger bar assembly which can be readily and easily manufactured, on a mass production basis, at a relatively low cost.

Other objects, features, and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings wherein like characters of reference designate corresponding parts throughout the several views and wherein:

FIG. 1 is a side elevational view of a hanger assembly constructed in accordance with the present invention, the hanger bar assembly being shown as disposed within a wardrobe-type shipping container which is illustrated in cross-section;

FIG. 2 is a plan view of the hanger bar assembly illus trated in FIG. 1;

FIG. 3 is an enlarged cross-sectional view taken substantially along line 33 in FIG. 2; and

FIG. 4 is an enlarged fragmentary exploded view of an end portion of the hanger bar illustrated in FIGS. 1, 2 and 3.

Referring now in detail to the embodiment chosen for the purpose of illustrating the present invention, it being understood that, in its broader aspects, the present invention is not limited to the exact details herein depicted, numeral 9 denotes generally a hanger bar which includes an inverted U-shaped hanger supporting bar 10, intermediate portions 20 and mounting hooks 30. The hanger support bar 10 includes a pair of spaced, opposed, upwardly tapering, flat, rectangular sides 11 and 12, the upper edges of which terminate in a common plane and are joined together by a horizontally extending flat rectangular web or upper plate 13. In cross-section, the hanger support bar 10 forms a downwardly opening trapezoid in which the distance between the parallel lower edges 14 and 15 of the sides 11 and 12 is greater than the distance between the upper parallel edges 16 and 17 thereof.

Each of the ends of the hanger bar 10 merges with the flaring intermediate portion 20, which projects outwardly and merges with its inverted U-shaped mounting hook 30.

In more detail, the intermediate portion 20 includes a substantially flat upper web 21 which is substantially trapezoidal in shape, the minor base of which merges with the edge of upper plate 13. The major base of web 21 forms a common edge 22 with the lower edge of the inner flange 31 of mounting hook 30.

The opposed outwardly diverging edges of the Web 21 are curved downwardly and merge with the opposed outwardly diverging sides 23 and 24 of the intermediate portion 20. Sides 23 and 24 are substantially triangular in shape, the base of the sides 23 and 24 respectively merging with the ends of sides 11 and 12.

Each mounting hook 30 includes the inner flange 31, an outer flange 32, and a connecting bearing plate 33. The flanges 31 and 32 are opposed parallel substantially complementary rectangular members, the upper parallel edges of which are joined by the curvilinear bearing plate 33. Plate 33 is essentially concave in crosss-section, and its lower edges merging with the upper edges of the flanges 31 and 32.

The integral, symmetrical hanger bar 9 is produced from a single rectangular sheet of metal in a single die operation. Therefore, prior to the stamping operation, the blank, from which the hanger bar 9 is formed, has parallel sides throughout its length. The initial width of the blank, of course, is approximately equal to the width of one of the hooks 30. After the stamping operation, the central portion of the blank which forms the hanger support bar 10 is deformed into trapezoidal shape throughout substantially the length of the blank, leaving only that portion of the metal which forms the opposed flaring portions 20 and the opposed hooks 30. From an examination of FIG. 1, it will be seen that the web 21 of the flaring portion 20 extends outwardly and downwardly after the die operation and, immediately prior to merging with the inner flange 31, the sides 23 and 24 taper to a flat portion with the web 21 so as to provide a width of metal equal to the width of the inner flange 31.

The flanges 31 and 32 of each hook 30 are substantially parallel to each other and are disposed essentially vertically, being normal to the plane of the upper plate 13 of the hanger support bar 10. The plane of the upper plate 13 is spaced downwardly from the plane of the upper extremities of the mounting hooks 30; however, the plane of the upper plate 13 is well above the plane of the lower extremities of the hooks 30.

According to the present invention, a plurality of spaced apertures, holes, or slots 34 are provided at spaced intervals longitudinally in the plate 13 of hanger support bar 10. Each aperture or slot 34, as illustrated in the drawings, is preferably an elongated, rectangular slot 34 which is disposed in alignment with other slots 34 essentially along the center line, i.e., equidistant from edges 16 and 17 of the hanger support bar 10. While it is a matter of choice as to how many such apertures, holes, or slots 34 to provide, I have found that usually only approximately three such holes 34 are necessary in a standard hanger bar of approximately 26 inches. Thus, preferably, there should be provided a central hole, slots or aperture 34 and a pair of outer holes, apertures or slots 34 on opposite sides of the central hole 34 adjacent but inwardly of the intermediate portions 20.

For cooperating with the hanger support bar in clamping the hooks 40 of hangers in place on the hanger support bar 10, I have provided a retaining or locking cap 41 which in cross-section is an inverted U-shaped member having rectangular sides 42 and 43 and a flat rectangular clamping plate 44 connecting the upper edges 42 and 43' of the sides 42 and 43. The sides 42 and 43 taper or converge upwardly while the width of the clamping plate 44 exceeds the width of the upper plate 13 whereby the sides 42 and 43 overlie the lower portion of the sides 11 and 12, as illustrated in FIG. 3. The clamping plate 44 is provided with a plurality of apertures, holes or slots 45 which are so spaced longitudinally along the center line of the retaining cap 41 that they are adapted to be aligned with the apertures 34 in the plate 13 when the retaining cap 41 is brought into registry with the hanger support bar 10, as illustrated in FIG. 3.

In use, the hooks 30 are disposed over the upper edges of the opposed side panels 51 and 52 of a conventional wardrobe-type corrugated container, denoted generally by the numeral 50. In boxes of this type, the upper edges of the panels 51 and 52 are formed by reversely bent portions including either outwardly or inwardly disposed flaps such as flaps 53 and 54. When the flaps 53 and 54 are outwardly of the panels 51 and 52, as illustrated in FIG. 1, intermediate flaps, such as flaps 55 and 56, join the top flaps, such as flaps 57 and 58, the flaps 53 and 54, respectively. When the container 50 is closed, the top flaps 57 and 58 are folded over the hanger bar while additional top flaps, such as flaps 59, extends over the flaps 56 and 57. Those skilled in the art will understand the arrangement of the wardrobe-type corrugated container 50.

The wardrobe-type corrugated container 50 is usually loaded either from the top or through an access door (not shown). If it is loaded from the top using the hanger bar assembly of the present invention, a plurality of articles of apparel, disposed on conventional hangers, are arranged with the hooks 40 of the hangers extending over and being carried by the hanger support bar 10 is spaced side-by-side relationship. Then, the hanger bar 9, carrying the articles of apparel on the hangers, is lowered into container 50 and the hooks 30 forced downwardly on the upper edges of panels 51 and 52, as illustrated in FIG. 1.

In order to prevent the hooks 40 from being inadvertently moved laterally in the container 50, i.e., longitudinally of the hanger support bar 10, or being inadvertently removed from the hanger support bar 10, the locking cap 41 is brought down upon the upper surface of the hanger hooks 40 and the cap 41 is so manipulated as to align the openings or holes therein in alignment with the openings or holes 34.

Thereafter, a short, flat, rectangular length of deformable metal, such as aluminum of a length exceeding the width of the assembled cap 41, hooks 40, and hanger support bar 10 is bent to an L-shape, as illustrated in FIG. 4. In cross-section, the deformable metal is less wide than the length of the hole 34 or 45 and less thick than the width thereof. One leg is passed through a pair of the alinged holes 34 and 45. The metal is then bent, as illustrated in FIG. 3, to form a retaining clip 46. In bending the retaining clip 46, the lower end of the clip is preferably bent forwardly in the same direction as the upper leg of the clip 46 so that the ends of the clip 46 extend outwardly of sides 11 and 42 or the sides 12 and 43 as the case may be. Thereafter, the ends 47 and 48 of the clip 46 are bent toward each other, the length of clip 46 being such that its ends 47 and 48 terminate in spaced relationship to each other. Thus, the clip 46, as bent, includes a lower reversely bent portion and an upper reversely bent portion.

If a flat piece of metal is used for forming the clip 46, it is passed through the aligned holes 45 and 34, and is so arranged in the holes 45 and 34 that a portion of the lower portion of the metal projects below the hanger support bar 10 and the upper portion thereof projects above the retaining cap 41, the metal is bent to one side with its lower protruding portion being bent around the lower edge 14 or 15 of the sides 11 or 12 and the upper protruding portion of the metal being bent at substantially right angles and down so as to lie flat against and conform to the contour of the upper surface of plate 44 and protrude over one edge thereof and downwardly over one of the depending sides 42 or 43. Similarly bent clips 46 are provided for the other pairs of aligned holes 34, 45.

Of course, when the shipping container or wardrobe box is to be unloaded, the metal clips 46 are straightened sufficiently to permit the removal of the locking cap 41.

It will be seen in FIG. 3 that when the locking cap 41 is in position and is held by the clips 46, the sharp edges 49 of the sides 42 and 43 engage the hanger books 40 at spaced intervals, as the edges 16 and 17 carry portions of each hanger hook 40 inwardly of the engaged portions. Furthermore, the inner surface or lower surface of the plate 44 may engage the upper surface of the hooks 40 and/or may be flexed downwardly by clips 46 for resiliently urging the edges 49 into engagement with the hooks 40. With some types of hooks, the side 12 may also engage a portion of the hook and, indeed, due to the trapezoidal shape of the hanger support bar 10, the lower edge 15 may also engage a portion of the hanger hooks 40. Thus, the hooks 40 are prevented from shifting laterally to any appreciable extent and are positively restrained against being inadvertently removed during shipment.

The trapezoidal shape of the hanger support bar 10 also enables the hanger bar 9 to be readily removed from the die after having been formed. Likewise, the trapezoidal shape of the locking cap 41 also facilitates the ready removal of the cap 41 from the die after the cap 41 is formed. It will be remembered that the hanger bar 9 may be formed with a single die operation. Furthermore, the cap 41 may be formed with a single die operation. Therefore, the hanger bar assembly of the present invention is quite economical to manufacture.

The shape of the webs 21 and the sides 23 and 24 impart rigidity to the hanger support bar 10 and enable it to support a relatively heavy load without permanent deformation of the hanger bar 9. Furthermore, the attachment of the cap 41 by means of the clips 46 lends additional rigidity to the assembly while, at the same time, locking the hooks 40 in place.

It will be obvious to those skilled in the art that many variations may be made in the embodiment here chosen for the purpose of illustrating the present invention, without departing from the scope thereof, as defined by the appended claims.

I claim:

1. In a hanger bar assembly of the type having a hanger support bar over which a plurality of hooks of hangers are disposed for supporting articles of apparel on the hangers from the hanger bar, the combination therewith of a locking cap disposed over the upper surface of said hanger support bar, said hanger support bar and said locking cap being provided with a plurality of spaced holes respectively aligned with each other when said cap is disposed over said hanger support bar, and a plurality of deformable clips respectively received in said aligned holes, said clips each being in a bent condition outwardly of said holes for preventing removal of said locking cap from said support bar, the upper end portions of said clips extending over the upper surface of said locking cap, the lower end portions of said clips passing around the lower edge of the side of said hanger support bar.

2. The structure defined in claim 1 in which at least certain of the aligned holes in said hanger support bar and said locking cap are elongated slots.

3. The structure defined in claim 1 wherein said hanger support bar is an inverted U-shaped member having a flat upper plate in which said holes are disposed.

4. The structure defined in claim 1 wherein said hanger support bar is an inverted U-shaped channel member having the holes therein along the upper surface of said hanger support bar and wherein the lower end portion of each of said clips form an acute angle around the lower edge of the side of said hanger support bar, and the upper end portion of each of said clips projects downwardly beyond the edge of said locking cap.

5. In a hanger bar assembly of the type having a hanger support bar over which a plurality of hooks of hangers are disposed for supporting articles of apparel on the hangers from the hanger support bar, said hanger support bar being provided with a fiat upper surface and a pair of opposed sides depending from the edges of said upper surface, the combination therewith of a locking cap disposed over the upper surface of said hanger support bar, said locking cap having a flat clamping plate provided with a pair of sides adapted to overhang the sides of the hanger support bar, and means for securing said hanger support bar and said locking cap in clamping condition for arresting the movement of the hangers supported on said hanger support bar, said means includes a plurality of clips, said hanger support bar and said cap being provided with aligned holes through which said clips project, said clips being deformed laterally for locking the cap in place.

References Cited UNITED STATES PATENTS 2,366,085 12/1944 Brothers 211123 X 3,298,503 1/1967 Field 21 1124 3,306,465 2/1967 Brennan 211--124 CHANCELLOR E. HARRIS, Primary Examiner. 

